IntElect 50-210
The quantum leap in full electric machines
"Top-of-the range precision at a high price" was the industry`s assessment of all-electric injection molding machines. Hence, their use was restricted to the production of precision parts mainly for medical engineering and electrical engineering applications. That was then – this is now!
Demag Plastics Group is extending the modular drive philosophy it had started with its EL-EXIS into the domain of all-electric machines.
A trendsetting concept, it provides for each movement axis of the machine to be equipped with optimally suited electrical drives – all featuring the latest state of the art technology with economic superiority. The result is an all-electric machine that sets new benchmarks in terms of process consistency, reproducibility, reliability, and energy usage. And also in terms of maintenance costs.
Equipped with water-cooled direct drives for all movement axes, the IntElect achieves an extremely high degree of precision.
Experience gathered over the last few years has directly gone into product improvement. With the new construction series, further high-speed versions with up to 500 mm/s will be introduced. The dry-running time for the machines of the new construction series was reduced by more than 20%.
Additionally, the mechanical design of the new IntElect draws on the expertise accumulated over many decades of innovative development efforts. With such features as the powerful and sensitive five-point double toggle, rugged con-struction, and thoroughly ergonomic design, an intelligent operator environment, and the familiar modular options, the IntElect opens up entirely new possibilities for the growing number of high-precision applications.
The IntElect`s benefits at a glance:
Precise: Exceptionally high process consistency and reproducibility through high-torque direct drives
Economical:Up to 60 % less energy consumption compared to hydraulic machines; recovery of braking energy to meet energy requirements of other axes
Low price: Reduction in drive components; does without expensive mechanical transmission components
Fast: Cycle time minimised thanks to freedom in designing machine sequences and parallel movements
Reliable: Minimum upkeep expense through reduction in the number of moving components needing maintenance
Clean: Meets cleanliness standards to ISO Class 7 (class 10,000 rating) thanks to belt-less direct drives for the main movements and water-cooled motors and converters
Quiet: Human sound sensation halved compared to conventional all-electric (belt-drive) machines; reduced by about 75 % compared to hydraulic machines
Flexible: Many options available from Demag‘s modular range for 500, 800, 1,000, 1,500, and 2,100 kN clamping force
The clamping unit
The 5-point, double-toggle type clamping unit with liberal tiebar clearances offers ample space for large moulds.
The powerful kinematics of the double toggle make for short locking times and high mould-opening forces. The closing and opening processes are controlled with high precision in order to cause no damage to the mould.
And if any irregularities should occur in closing, there is the active mould protection system which stops the machine within milliseconds and reliably protects high-cost precision moulds from damage.
Drives
Direct drives are here to stay. Their merits have caused us to power all main axes of the IntElect with independent drives: High-torque direct drive for the mould movements. High-torque direct drives for metering, plasticising, and injection. Separate drives for the secondary movements. This decentralized solution not only makes machine movements more reliable, faster and more precise - it also cuts energy and cooling power requirements and provides substantial savings in first cost and maintenance expense. Two high-torque direct drives ensure an outstanding process consistency an reproducibility by delivering a highly repeatable screw end position and a precise change-over from injection to cavity pressure with minimum deviations. The clamping unit`s high-torque drive operates with high-precision sensor technology. In combination with the machines five-point double toggle clamp, this system generates precise and fast machine movements.
The injection unit
The modular concept of the injection unit affords a high degree of flexibility: for each clamp size, the Demag modular range provides a choice of three injection units, each with three screw cylinders. Different screw geometries are available for speciality plasticising jobs. The quick-connect coupling of the screws enables plasticising units to be changed quickly and easily.